New energy vehicles

Preventing hazards in e-mobility battery pack assembly: how can it be achieved?

September 29, 2023

The Mobility sector is experiencing a drastic huge change due to the massive transition to electric vehicles (EV) which are highly eco-friendly.

The battery is one of the most expensive components in an electric car. It is composed of many modules connected to each other creating high voltages of up to 800 volts which are critical for the security and overall performance of the vehicles.

Those characteristics and specifications make an e-mobility battery pack assembly very risky without the right precautions.

Electric car assembly

So, what are the dangers and unique challenges faced during electric cars production? And how can production managers control those risks and ensure an optimized electric car assembly hazard management?

In collaboration with our experts, we have released a white paper that introduces and explains the challenges and risks of e-mobility assembly in addition to some safety and security recommendations for an optimized control of the production line. Also, it contains some new innovative solutions to manage e-mobility assembly hazards that have been tested and approved by Dekra (in conjunction with the tools according to IEC 60900:2018, IEC 60664-1, EN 60745-1).

This white paper will help you to establish the best strategies of safety and security management for your work environment.

1. The risks of electric cars assembly such as:

  • Electrification and electrical accidents due to the contact with live parts
  • Electrical shocks and their potential impacts
  • Electric arc in the event of short circuits

2. The solutions to secure your assembly line such as:

  • Specific insulated tools to avoid short circuits or any unwanted contacts with high-voltage components
  • Transducer-based tightening tools equipped with torque and angle sensors
  • Screw feeder solution, positioning system and multi bolt spindle solutions for high assembly quality